Multi-step system for processing workpieces

ABSTRACT

Systems, including method and apparatus, for processing workpieces driven automatically along a linear path to a plurality of positions disposed substantially along the linear path. In some embodiments, a workpiece may be processed at one or more of the positions using two or more processing stations, such as a first processing station that cuts the workpiece into segments and a second processing station that performs another processing operation on the workpiece.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation patent application of U.S. patent applicationSer. No. 11/702,905 filed Feb. 5, 2007 which is a continuation patentapplication of U.S. patent application Ser. No. 10/964,553 filed Oct.12, 2004, now U.S. Pat. No. 7,171,738 issued Feb. 6, 2007.

CROSS-REFERENCES TO RELATED MATERIALS

This application incorporates by reference the following U.S. Pat. Nos.491,307; 2,315,458; 2,731,989; 2,740,437; 2,852,049; 3,886,372;3,994,484; 4,111,088; 4,144,449; 4,286,880; 4,434,693; 4,541,722;4,596,172; 4,939,379; 4,658,687; 4,791,757; 4,805,505; 4,901,992;5,042,341; 5,142,158; 5,201,258; 5,251,142; 5,254,859; 5,443,554;5,444,635; 5,460,070; 5,524,514; 5,960,104; 6,216,574; 6,549,438; and6,631,006.

This application also incorporates by reference the following U.S.patent applications: Ser. No. 10/104,492, filed Mar. 22, 2002; Ser. No.10/642,349, filed Aug. 15, 2003; Ser. No. 10/642,350, filed Aug. 15,2003; Ser. No. 10/642,351, Aug. 15, 2003; Ser. No. 10/645,826, filedAug. 20, 2003; Ser. No. 10/645,827, filed Aug. 20, 2003; Ser. No.10/645,828, filed Aug. 20, 2003; Ser. No. 10/645,831, filed Aug. 20,2003; Ser. No. 10/645,832, filed Aug. 20, 2003; Ser. No. 10/645,865,filed Aug. 20, 2003; Ser. No. 10/897,997, filed Jul. 22, 2004; and Ser.No. 10/958,690, filed Oct. 4, 2004, titled “System for Forming Dados,”and naming Spencer B. Dick, as inventor.

This application also incorporates by reference the following U.S.provisional patent application: Ser. No. 60/574,863, filed May 26, 2004.

BACKGROUND

Many manufactured goods are constructed from components that are cutfrom stock material, processed further, and then assembled. For example,wood products, such as cabinets, often are constructed in a series ofoperations including cutting components of the appropriate length fromstock lumber, modifying each component to facilitate assembly (and/or toadd functionality and/or improve appearance), and then assembling themodified components. Performing of these operations can be inefficient,even when one or more of the operations are automated. For example, anautomated saw may use a computer to determine where to cut stock lumberfor construction of cabinets according to a user-supplied list of therequired lengths of cabinet components (i.e., a cut list). The computercontrols sites of cutting along the stock lumber based on the cut listand in a manner that optimizes utilization of the lumber to create thecabinet components. However, the cabinet components are generallyhandled to reposition them between cutting and further modification(such as drilling, marking, forming a joint surface, etc.), addingsubstantial time and expense to the construction of cabinets. A moreefficient approach to processing components from stock material thus isneeded.

SUMMARY

The present teachings provide systems, including method and apparatus,for processing workpieces driven automatically along a linear path to aplurality of positions disposed substantially along the linear path. Insome embodiments, a workpiece may be processed at one or more of thepositions using two or more processing stations, such as a firstprocessing station that cuts the workpiece into segments and a secondprocessing station that performs another processing operation on theworkpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary system for processingworkpieces driven along a linear path past a plurality of processingstations disposed generally along the linear path, in accordance withaspects of the present teachings.

FIG. 2 is a schematic view of a controller and data input/output devicesof the system of FIG. 1, in accordance with aspects of the presentteachings.

FIG. 3 is a flowchart of a sequence of operations that may be performedin an exemplary method of processing workpieces at two or moreprocessing stations, in accordance with aspects of the presentteachings.

FIG. 4 is a view of an exemplary system for drilling and cuttingworkpieces driven along a linear path past a drill station and a sawstation, in accordance with aspects of the present teachings.

FIG. 5 is a view of selected portions of the system of FIG. 4,particularly the drill station and saw station and their relationship toan exemplary workpiece, in accordance with aspects of the presentteachings.

FIG. 6 is a schematic side elevation view of selected portions ofanother exemplary system for processing workpieces at a plurality ofprocessing stations, particularly showing a print station printingindicia on a workpiece driven past the print station, in accordance withaspects of the present teachings.

FIG. 7, is a plan view of the system of FIG. 6, taken generally alongline 7-7 of FIG. 6.

FIG. 8 is a somewhat schematic view of selected portions of stillanother exemplary system for processing workpieces at a plurality ofprocessing stations, particularly showing a marker station marking aworkpiece with transverse lines, in accordance with aspects of thepresent teachings.

FIG. 9 is a somewhat schematic, partially sectional view of selectedportions of yet another exemplary system for processing workpieces at aplurality of processing stations, particularly showing a spacerplacement station firing spacer balls into a longitudinal groove of aworkpiece as the workpiece is moving past the placement station, inaccordance with aspects of the present teachings.

DETAILED DESCRIPTION

The present teachings provide systems, including method and apparatus,for processing workpieces driven automatically along a linear path (aprocessing path) to a plurality of positions disposed substantiallyalong the linear path. In some embodiments, a workpiece may be processedat one or more of the positions using two or more processing stations.One of the processing stations may be a cutting station, for example asaw station, that cuts through the workpiece to create segments (asegmented form of the workpiece). A computer may receive data about theworkpiece, such as its length, positions of one or more defects, if any,in the workpiece, and a cut list defining a characteristic dimension(e.g., the length) of each of a set of desired products. The computermay select sites along the workpiece where cutting is to be performed,according to the cut list and to optimize use of the workpiece (and,optionally, to exclude one or more defects of the workpiece from each ofthe workpiece products). The computer also may control operation of aworkpiece drive mechanism that moves the workpiece along the linear pathfor cutting at the selected sites by the cutting station to producesegments corresponding in length to one or more of the desired products(unless slated to be shortened by additional processing). Otherprocessing operations (such as drilling, marking, routing, sawing atanother saw station, sanding, deburring, fluid addition, memberaddition, etc.) also may be performed on the workpiece, generally undercontrol of the computer, during a single pass of the workpiece past theprocessing stations. Accordingly, the systems of the present teachingsmay offer increased automation, more rapid workpiece processing, lessoperator handling, and/or higher production efficiencies, among others.

FIG. 1 shows an exemplary system 20 for processing workpieces with twoor more processing stations. System 20 may include a drive mechanism 22for moving a workpiece 24 along a linear path 26. In the presentillustration, drive mechanism 22 is configured as a pusher mechanism orpusher 28 that engages a distal end region 30 of the workpiece andadvances (and stops) adjustably, indicated in phantom outline at 32, topush the workpiece forward. The drive mechanism may move the workpiecepast two or more processing stations disposed generally along and/oradjacent the linear path. In the present illustration, system 20includes three processing stations 34, 36, 38 (labeled “A,” “B,” and“C,” respectively). However, two, four, or more processing stations maybe included. The processing stations may modify the workpiece atpositions, shown at 40, substantially along the linear path to form oneor more workpiece products.

System 20 also may include at least one controller 42 (a computer) incommunication with drive mechanism 22, shown at 44, and generally alsoin communication with each processing station, shown at 46. A controlleror computer, as used herein, is any programmable electronic machine forprocessing information (data). The controller is configured to controloperation of the workpiece drive mechanism, to move the workpieceautomatically into position for modification by the processing stations.In some examples, the controller also may be configured to controloperation of one or more (or all) of the processing stations, toautomate modification of the workpiece during and/or after movement ofthe workpiece into and/or through processing stations. Data thus may bereceived by the controller and/or sent from the controller usingcommunication pathways, such as communication links 44, 46 and/or datainput/output devices 48. The terms “automatically” and “automated,” asused herein, refer to operations or processes (or processing stations)that do not require human intervention for their execution (or actuationin processing). For example, processing a workpiece automatically with apusher mechanism and one or more processing stations means that thepusher mechanism and the one or more processing stations can operate incoordination to modify the workpiece without human intervention afterthe pusher mechanism begins moving the workpiece toward the processingstations. The term “manually” or “manual,” as used herein, refer toprocesses or operations (or processing stations) that involve humanintervention for their execution (or actuation in processing). In someexamples, one or more of the processing stations may be operatedmanually during processing, for example, a saw station that cutsworkpieces with manual movement of a power-driven blade of the stationthrough workpieces.

FIG. 2 shows an exemplary schematic configuration of selected portionsof controller 42 and connected input/output devices 48.

Controller 42 may include a processor 60 and memory 62, among otherdevices. Processor 60 may be configured to process data, for example, byperforming arithmetic, logical, and/or other operations on the data.Memory 62 may include input data 64 received, for example, fromcommunication links 44, 46 (see FIG. 1) and/or input/output devices 48.Memory also may include instructions 66, generally in the form ofsoftware, for processing data and/or instructing operation of theworkpiece drive mechanism, processing stations, and/or other devices ofthe system.

Input data 64 may include any suitable data related to workpieces,products, modes of processing, user-defined preferences for processingor system operation, etc. Exemplary input data may include product data68 and workpiece data 70.

Product data 68 may be information about desired products and/or aboutworkpiece products already produced by the system, among others.Information about desired products may include a cut list 72 with cutlist data corresponding to a characteristic dimension (e.g., the length)of each desired product (and/or longer precursors (of the desiredproducts) that are slated for additional shortening in the system, suchas by processing of newly cut ends). Accordingly, the cut list maydefine the spacing between cuts within a workpiece and/or between a cutand the end of the workpiece, among others. The cut list (and/or theproduct list) also may provide data corresponding to the relative orabsolute number of each desired product that the system should produce.Information about desired products also or alternatively may includedata corresponding to a list of other processing operations, shown at74, to be performed on workpieces. For example, the list of otherprocessing operations may include a drill list with data correspondingto positions on desired products at which holes should be formed (and/orthe depth/angle of each hole), a joinery list with data corresponding tojoinery structures (e.g., joint surfaces) to be created in desiredproducts, a marking list with data corresponding to positions at (andcontent of) surface marks to be created on each desired product, etc.Accordingly, the list of other processing operations may be related todesired products having lengths formed by cutting workpieces, althoughthese other processing operations may be conducted before, during,and/or after workpieces are cut into segments having lengthscorresponding (approximately or substantially) to desired products. Insome examples, other processing operations may be specified byprocessing rules that allow processing positions to be calculated foreach desired product based, for example, on the length of the desiredproduct. Exemplary processing rules may include processing at thelongitudinal midpoint of a desired product, processing at a constantspacing from the opposing ends of a desired product, etc.

Workpiece data 70 may be information about any suitable aspect of aworkpiece to be processed by the processing stations of the system.Exemplary workpiece data may include a characteristic dimension (e.g.,the length, width, and/or thickness, among others) of the workpiece,grade of workpiece (and/or its material), type of workpiece,composition, shape, appearance (such as its color), defect data (e.g.,position(s), type of defect, degree of defect, etc.), and/or the like.Further aspects of workpieces and data that may be input aboutworkpieces are included in Sections IV and V.

Instructions 66 may be configured to use input data 64 about a workpieceand desired products, among others, to generate processing instructionsthat control automated operation of the workpiece drive mechanism and/orthe processing stations (see FIG. 1).

Exemplary instructions may include an optimization algorithm 76. Theoptimization algorithm may be configured to optimize utilization of eachworkpiece based on data about desired products (and, optionally, basedalso on products already produced). In particular, the optimizationalgorithm may be configured to optimize utilization of each workpiecebased on cut list 72. Accordingly, the optimization algorithm may selectsites along a workpiece at which the workpiece will be cut intosegments, based on desired products indicated by the cut list. The sitesmay be selected according to the length of the workpiece, theposition(s) and length of defects in the workpiece, and other aspects ofthe workpiece, such as the grade of workpiece material. Optimization ofthe use of a workpiece may include selecting cutting sites so thatworkpiece defects, if any (as determined by a person operating thesystem and/or automatically), are excluded from workpiece productsformed from the workpiece.

Other exemplary instructions may include a remainder managementalgorithm 78 to manage processing of remainder material. Remaindermaterial, as used herein, is one or more segments of a workpiece thatwill not be processed into workpiece products corresponding to desiredproducts. The remainder material may include a defect and/or may be aportion of the workpiece too short to form a product on the cut listafter cutting sites have been selected on the workpiece. The managementalgorithm may determine, for example, whether each remainder segmentshould be cut into smaller pieces or not. Accordingly, the managementalgorithm may determine, for example, whether each remainder segment isthrown away or salvaged. In some examples, the management algorithm maymanage sorting of workpiece products, alternatively or in addition tomanaging cutting and/or sorting of remainder material. Further aspectsof processing remainder material for salvage or disposal are included inU.S. patent application Ser. No. 10/645,828, filed Aug. 20, 2003, whichis incorporated herein by reference.

Additional exemplary instructions may include device drivers 80. Drivers80 may be responsible for control signals or instructions sent to theworkpiece drive mechanism and/or the processing stations, among others.A software driver for the workpiece drive mechanism may controloperation of this drive mechanism and thus movement of a workpiece alonga linear path. Drivers for the processing stations may control operationof each processing station, for example, by controlling a station drivemechanism for each station. Exemplary aspects of control for theworkpiece drive mechanism (and/or workpiece), and/or processing stationsmay include speed, acceleration, distance of travel, startingposition(s), stopping position(s), and/or actuation/de-actuation times,among others. In some examples, aspects of the controller, andparticularly device drivers, may be included in the workpiece drivemechanism and/or processing stations.

Data input/output devices 48 may be disposed in communication with thecontroller.

Exemplary input/output devices may include one or more user interfaces82, such as a keyboard, a keypad, a mouse, a screen, and/or a joystick,among others, to allow an operator to input data to the controller, forexample, by pressing keys and/or through a graphical user interface.Alternatively, or in addition, the operator may input data more directlyinto controller memory from a portable memory storage device holdinginput data that was added to the storage device using another computingdevice.

Other exemplary input/output devices may include at least one sensor 84,such as a distance, position, velocity, or activity sensor, amongothers. The sensor may be configured, for example, to permit an operatorto input data about workpieces (e.g., dimensional, defect, and/or gradedata, among others), and/or may sense this data automatically (e.g., bysensing an end and/or defect of the workpiece and/or by sensingmachine-readable indicia on the workpiece). In some examples, a sensormay be configured to sense manual operation of a processing station by aperson during otherwise automated processing. For example, the sensormay inform the computer that a person has performed a cut in aworkpiece, so that the computer can instruct the drive mechanism toadvance to workpiece for additional processing or output.

Addition exemplary input/output devices may include one or more printers86 to output data. The printer may be configured, for example, to printdata about workpieces, workpiece processing (such as numbers/types ofproducts, time of processing, etc.), user preferences, etc.Alternatively, or in addition, the printer may be configured to printlabels for workpiece products. The labels may be applied manually orautomatically to the products. Further aspects of label printing areincluded in U.S. patent application Ser. No. 10/645,831, filed Aug. 20,2003, which is incorporated herein by reference. In some examples, aprinting device (a printhead) may be included in a processing station toapply a colorant (such as ink) to a workpiece (see Examples 2 and 3).

In some examples, the input/output devices may include one or moreaudio/visual devices 88. Each audio/visual device may be configured tocreate an audible or visible signal for an operator of the system.Exemplary audible signals may include a buzzer, a bell, a tone, awhistle, a spoken word, and/or the like. Exemplary visible signals mayinclude a light(s). The light or lights may be of different colors,intensities, positions, and/or flashing durations/patterns, amongothers, to signal different information. The signals may be configuredto indicate any suitable aspect of data input, data output, workpieceprocessing, and/or system operation, among others. For example, thesignals may indicate that data (such as workpiece length, grade, defectposition(s)) has or has not been input successfully, that workpieceprocessing has been initiated, that workpiece processing is complete, amalfunction of the system, etc.

FIG. 3 shows a flowchart of method steps that may be performed in anexemplary method 110 of processing workpieces at two or more processingstations in a processing system. The steps shown may be performed in anysuitable order, in any suitable combination, and any suitable number oftimes.

Inputs may be received, shown at 112. The inputs may be received by acontroller and may include any data related to a workpiece to beprocessed, desired products, processing parameters, system parameters,and/or the like. The inputs may be provided to the controller from anoperator, automatically (such as from a sensor), and/or by dataprocessing, among others.

Processing instructions may be determined based on the inputs, shown at114. The processing instructions may include any aspects of how theworkpiece drive mechanism, processing stations, and/or other systemdevices operate. For example, the processing instructions may includewhere (and/or when/how) the workpiece drive mechanism (and generally theworkpiece) starts and stops, when (and/or where/how) the processingstations modify the workpiece, and/or the like.

The workpiece may be positioned adjacent (and/or in) two or moreprocessing stations, shown at 116. A workpiece positioned adjacentand/or in a processing station is disposed to be engaged by a portion ofthe processing station and/or a component released therefrom (such as anexpelled component, e.g., ink, a fastener, a spacer element, etc.).

The workpiece may be processed with each processing station, shown at118. The action of the processing stations forms one or more workpieceproducts.

Further aspects of the present teachings are described in the followingsections, including, among others, (I) processing stations, (II) drivemechanisms, (III) support/guide structures, (IV) workpieces, (V) inputof workpiece and product data, and (VI) examples.

I. PROCESSING STATIONS

The systems of the present teachings each may include two or moreprocessing stations for processing workpieces. The term “processing,” asused herein, can be any action or set of actions that result instructural modification of a workpiece. A structural modification is anychange in the shape, size, a surface aspect, and/or other intrinsicproperty of a workpiece, for example, by removing material from theworkpiece, adding material to the workpiece, deforming the workpiece,and/or changing the molecular structure of the workpiece, among others.Accordingly, a processing station is any portion of a system that caneffect processing of a workpiece. Each processing station generallyincludes a machine or set of machines configured to perform a processingoperation, and an associated space in which the processing can beperformed on a workpiece. A system with two or more processing stationsmay include distinct processing stations that perform two or moredifferent types of processing operations and/or that can perform thesame type of processing operation at different positions (for example,at the same time).

A processing station may include a processing element that engages aworkpiece and/or ejects a material or projectile toward the workpiece.Exemplary processing elements that engage a workpiece may include ablade, a drill bit, a router bit, a pen, a tip, a scribe, a brush, etc.Exemplary processing elements that eject (or fire) a material orprojectile toward the workpiece, with, or more generally withoutworkpiece contact, may include a printhead, a sprayer, a dropper, aprojectile gun, etc. (Exemplary projectiles may include spacers,fasteners, joint members (e.g., dowels, biscuits, butterfly locks,etc.). and/or the like. Processing elements may have any suitabledisposition and/or direction of travel relative to a workpiece. Forexample, processing elements may be disposed above, below, laterally,and/or adjacent an end of the workpiece (and/or a segment thereof).Furthermore, processing elements may be movable translationally and/orpivotably, in any suitable direction, including downward, upward,transverse, oblique, and/or longitudinal motion, among others, relativeto the workpiece. This motion may position the processing element at asuitable position along the length, width, and/or depth of theworkpiece, and in some examples (e.g., drilling, sawing, and/or routing,among others), may introduce the processing element into and/or throughthe workpiece. Accordingly, the processing elements may be configured toprocess faces, edges and/or ends of workpieces.

Movement of processing elements, termed processing movement, to disposethe elements in operational position relative to workpieces, isgenerally computer controlled. However, processing elements also mayhave a basic repetitive operating motion, such as rotation,reciprocation, and/or travel along a looped path, among others, whichmay be actuated separately by an element driver, and thus may or may notbe computer controlled.

The processing stations of a system may have any suitable positional,functional, and operational relationship. Two or more of the processingstations may be disposed upstream and downstream of one another,generally along a processing path. Alternatively, or in addition, two ormore of the processing stations may have about the same position alongthe processing path, for example, when the processing stations occupysubstantially nonoverlapping positions around the workpiece. Theprocessing stations may have a fixed or adjustable positionalrelationship relative to one another (and/or to the workpiece),particularly along the processing path of the workpiece. Accordingly, insome examples, the processing stations may be movable to the sameposition in the processing path. The processing stations may performprocessing operations on a workpiece at any suitable relative times. Forexample, the processing stations may operate in a sequential manner onthe same region of the workpiece (e.g., forming a cavity in a regionwith a first station, and then placing a component in the cavity with asecond station), may operate at overlapping times on the workpiece(e.g., cutting a workpiece at a saw station as the workpiece is beingdrilled at a drill station), and/or may operate at non-overlapping timeson the workpiece (e.g., processing a workpiece using a station andduring a first time period (or a first set of intervals), while theworkpiece is moving, and processing the workpiece using another stationand during a second, nonoverlapping time period (or set ofnonoverlapping intervals), while the workpiece is not moving).Processing operations performed with two or more processing thestations, and workpiece movement, all may be coordinated by computer.

A processing station may be configured for removing material from aworkpiece, to change the shape, size, and/or a surface aspect of theworkpiece. Exemplary processing stations for removing material include asaw station (or another cutting station including a laser, knife, flame,electron beam, etc.) for cutting a workpiece, a router station forrouting/milling a workpiece, a scorer station for scoring the surface ofa workpiece, a sander station for smoothing the surface of a workpiece,a hole-forming or drill station for forming a hole in a workpiece, aborer station for widening a hole in a workpiece, a shearer station forshearing a workpiece, a deburrer station for deburring a cut end and/orother surface of a workpiece, a V-groove station for cutting a V-groovein a workpiece, a punch station for punching a hole in a workpiece,and/or the like.

A saw station may include any suitable type of saw, saw blade, bladeorientation, and blade movement. Exemplary blades may include circularblades, band blades, and/or reciprocating blades, among others. Theblades may be configured to perform crosscuts (generally transverse tothe length of a workpiece; e.g., chop saws), rip cuts (generally alongthe length of a workpiece; e.g., rip saws), miter cuts, dado cuts, anglecuts, nonlinear cuts, etc. The saw station thus may include a motor thatdrives the blade rotationally (e.g., circular saws), around a loop(e.g., band saws), and/or back and forth (e.g., reciprocating saws). Thedriven saw blade may be configured to be actuated for cutting aworkpiece by movement of the driven blade, generally computer-controlledmovement, in any suitable direction relative to a workpiece, includetranslationally (e.g., a radial arm saw) and or along an arc throughpivoting motion (e.g., a chop saw, using an upward and/or downwardmotion).

A drill station may include any suitable components and may operate byany suitable approach to a workpiece. The drill station may include adriver and a drill bit rotated by the driver. Positioning of drill bitmay be controlled by computer. This positioning may be parallel to thelong axis of the drill bit (to control depth of drilling forthrough-holes or recesses), and/or transverse to this axis. Accordingly,the depth of drilling may be controlled, to form through-holes orrecesses. Also, the transverse, longitudinal, and/or vertical positionof hole formation on a workpiece may be controlled, as may the angle ofhole formation. Alternatively, or in addition, one or more aspects ofthe position of the driver may be set manually before the workpiece isprocessed.

A processing station may be configured to add material to a workpiece,to change the shape, size, and/or a surface aspect of the workpiece.Exemplary processing stations for adding material include a printstation for adding one or more surface marks (an indicium or indicia) toa workpiece, a fastener station for adding a fastener to a workpiece(such as a nail, screw, bolt, rivet, bracket, hook, staple, dowel,biscuit, butterfly lock, spline, etc.), a coating station for adding asurface coating or fluid (e.g., paint, varnish, stain, sealant, glue,etc.) to a surface or surface region of a workpiece, a spacer stationfor adding a spacer element (e.g., a spacer ball, a block, a spline,etc.) to a workpiece, an assembly station that connects (e.g., joins)the workpiece with one or more other components, and/or the like.

A processing station may be configured to change the shape of aworkpiece by deformation of the workpiece. Exemplary deformation mayinclude bending, twisting, folding, compression, stamping, and/or thelike.

A processing station may be configured to change the molecular structureof a workpiece. Exemplary operations that may be used to change themolecular structure of a workpiece, either globally or locally in theworkpiece, may include heating, cooling, exposure to electromagneticradiation (e.g., visible light, radiofrequency waves, microwaves,ultraviolet light, X-rays, gamma-rays, etc.) or particle radiation,compression, and/or the like.

II. DRIVE MECHANISMS

The systems of the present teachings each may include any suitablenumber of drive mechanisms. Each drive mechanism may be configured tomove workpieces, workpiece products, a processing station(s), aprocessing element of a processing station, and/or the like. Drivemechanisms may be configured to move workpieces, products, stations,and/or elements translationally, rotationally, and/or pivotally, amongothers.

Operation of all or a subset of the drive mechanisms of a processingsystem may be computer controlled. A computer thus may control when adrive mechanism is actuated (movement starts), de-actuated (movementstops), the speed of the drive mechanism, acceleration of the drivemechanism, the direction of the drive mechanism, and/or the like. Thedrive mechanism may include an encoder that informs the computer of theposition, speed, velocity, acceleration, and/or direction of a drivemechanism.

Each drive mechanism may include a motor and a mechanical linkage thatcouples operation of the motor to movement of a load. The load mayinclude a conveyor belt, a pusher element that engages a distal end ofthe workpiece, and/or a portion or all of a processing station, amongothers.

Any suitable motor(s) may be used in the drive mechanism. Each motor maybe an AC or DC electric motor, or may be air-powered or gas-powered,among others. Exemplary motors may be single or multiphase, universal,servo, induction, synchronous, stepper, and/or gear motors. Each motormay rotary or linear.

The drive mechanism may employ any suitable linkage to the load.Exemplary linkages may include a belt(s), a screw(s), a gear(s) (e.g., aworm gear), a chain(s), a cable(s), a pulley(s), a rod(s), a rack andpinion, and/or the like. The linkage also may include a guide structureor track that directs and/or facilitates sliding movement of the load.Accordingly, the guide structure or track may include bearings or otherelements that promote sliding.

Workpieces may be moved along a linear path by a workpiece drivemechanism. The workpiece drive mechanism may be configured to engage anysuitable surface of workpieces, such as a trailing end (as in a pushermechanism) to push the workpieces, a face or edge (e.g., using aconveyor belt or conveyor wheels, among others) to carry or propel theworkpieces, and/or a leading end region, to pull the workpieces. Inexemplary embodiments, the pusher mechanism may include a worm gearformed of a threaded rod, and a worm wheel connected to a pushercarriage. Further aspects of pusher mechanisms that may be suitable aredescribed in U.S. patent application Ser. No. 10/642,350, filed Aug. 15,2003, which is incorporated herein by reference.

Processed workpieces (products) may be moved away from processingstations by any suitable drive mechanism(s). In some examples, theworkpiece drive mechanism also may be used to push workpiece productsthrough an outfeed site after their processing is complete.Alternatively, or in addition, products may be moved actively by adistinct product drive mechanism. The product drive mechanism mayinclude a conveyor, for example, to carry the products farther,generally along the linear path of processing, to move the productslaterally, and/or to carry the products in a direction generallyopposite to the linear path. In some examples, the product drivemechanism may include a pusher mechanism that engages an edge ofproducts and pushes them out of the linear path, for example, down aramp and/or onto a conveyor.

A processing portion of a processing station may be moved by anysuitable drive mechanism. For example, processing stations may includedrive mechanisms that move processing portion of the stations relativeto workpieces, for example, into engagement with the workpieces or intosuitable proximity to the workpieces. The drive mechanisms thus may beoperated, generally by computer control, to position processing sites ona workpiece and/or to conduct processing. In some examples, processingstations, such as fixed printheads that print on workpieces, may lack adrive mechanism so that they are stationary during operation.

A processing station may use distinct drive mechanisms for driving aprocessing element in its basic operating motion (e.g., rotating acircular saw blade) and for driving processing of the element with theprocessing element (e.g., moving the rotating circular saw blade througha workpiece). The element drive mechanism may or may not be computercontrolled. However, the processing drive mechanism generally iscomputer controlled.

The systems of the present teachings may include a clamp mechanism thatholds a workpiece in place as it is being processed by a processingstation. The clamp mechanism may include a clamp member (or members)coupled to a drive mechanism, so that the clamp member can be moved intoengagement with the workpiece to effect clamping, for example, when theworkpiece is not moving, and can be moved out of engagement with theworkpiece to permit movement of the workpiece by the workpiece drivemechanism. Operation of the clamp drive mechanism may be under computercontrol (i.e., automated). An exemplary clamp mechanism is shown anddescribed in Example 1.

III. SUPPORT/GUIDE STRUCTURES

The systems of the present teachings may include various support and/orguide structures that support, guide, and/or facilitate movement ofworkpieces, processing stations, and/or processing portions ofprocessing stations. For example, the support structures may include atable on which workpieces can slide. The table may include a rail orrails that restrict lateral movement of the workpieces, thus, along withthe workpiece drive mechanism, defining the linear path along whichworkpieces are driven. The table and/or rails may include structuresthat facilitate sliding, such as wheels or bearings, among others.Processing stations may be attached to the table or to adjacent supportstructures. Upward and/or lateral movement of workpieces also oralternatively may be restricted or biased by a superior or lateral wheeland/or a clamp mechanism (see Section II). Further aspects of a wheelfor biasing movement and/or creating drag are described in U.S.Provisional Patent Application Ser. No. 60/574,863, filed May 26, 2004,which is incorporated herein by reference.

IV. WORKPIECES

The systems of the present teachings process workpieces. A workpiece, asused herein, is any piece of material that will be, or is being,processed by a processing system. Accordingly, a workpiece may be in araw or “unprocessed” form (before any processing by a system), in apartially processed form (during and/or after partial processing by thesystem), or in a fully processed form (after processing of the workpieceby the system has been completed and/or the workpiece has passed throughthe system). Each processing station of a system thus may process theraw form of the workpiece, a partially processed form of the workpiece(such as a workpiece cut into smaller pieces or segments (a segmentedform of the workpiece) and/or modified otherwise), or both. The fullyprocessed form of a workpiece, as used herein, is termed a workpieceproduct or product. Although “fully processed” by a first pass throughthe system, a product may be processed additionally outside the systemor during a second pass through the system.

A workpiece may have any suitable composition. Workpieces thus may beformed of wood, metal, plastic, fabric, cardboard, paper, glass,ceramic, or a combination thereof, among others. The composition may begenerally uniform or may vary in different regions of a workpiece (e.g.,a wood workpiece with a vinyl coating). Exemplary workpieces are woodproducts, for example, sawn lumber, wood laminates, wood composites,etc. Other exemplary workpieces are metal sheets or strips.

A workpiece may have any suitable shape and size. Generally, theworkpiece is elongate, so that the workpiece can be moved along a linearprocessing path that is parallel to the long axis of the workpiece.However, in some embodiments, the workpiece may not be elongate and/ormay not be oriented so that the long axis of the workpiece is parallelto the linear processing path. The workpiece may have any suitablelength. Exemplary lengths are based on available lengths of stockpieces, such as stock lumber of about six feet to twenty feet in length,for the purpose of illustration. In some examples, the workpiece mayhave a rectangular cross section, opposing ends, edges, and faces.

A workpiece may be of generic stock or may be pre-processed according toa particular application, before processing in a system. For example,the workpiece may be a standard piece of raw lumber. Alternatively, theworkpiece, before processing by the system, may include one or moreholes, grooves, ridges, surface coatings, markings, etc., created, forexample, based on desired features of products to be formed by thesystem.

V. INPUT OF WORKPIECE AND PRODUCT DATA

Data about workpieces and/or desired products may input into a system,by communicating this data to a controller. The data may be inputthrough any suitable user interface.

Any suitable data may be input about a workpiece. The data may relate tothe type of workpiece, one or more characteristic dimensions (e.g., thelength, width, and/or thickness, among others) of the workpiece, gradeof workpiece material (e.g., high grade, medium grade, low grade, etc.),composition, shape, defect data (e.g., defect position(s), degree ofdefect, etc.), color, and/or the like.

Workpiece data may be input through the action of a person and/orautomatically. Accordingly, the workpiece data may be input through acomputer interface, such as a graphical user interface, a keyboard, akeypad, etc. Alternatively, or in addition, the workpiece data,particularly one or more characteristic dimensions and/or defect dataabout of the workpiece, may be input through a controller-linkedmeasuring device. The measuring device may include an optical measuringdevice (e.g., see Example 1). Alternatively, or in addition, themeasuring device may be an encoder-based measuring device that anoperator can slide parallel to the length of a workpiece and selectivelyactuate, for example, by pushing a button, to send information about therelative position of the workpiece ends, one or more defects, and/orother workpiece features to the controller. Exemplary measuring devicesthat may be suitable for use in the processing systems of the presentteachings are described in the patents and patent applicationsidentified above under Cross-References, which are incorporated hereinby reference,

Any suitable data may be input about desired products to provide aproduct list. The data may correspond to the length of each product (acut list), the absolute or relative number desired of each product,type(s) of processing to be included in each product, position(s) whereprocessing should be performed for each product, order of processingoperations for each product, etc. In some examples, the data maycorrespond to a destination for the product, such as a bin or chute,among others, to which the product should be direct automatically, sothat products are sorted after processing.

VI. EXAMPLES

The following examples describe, without limitation, further aspects ofthe present teachings. These aspects include exemplary systems forprocessing workpieces driven along a linear path through (and/oradjacent) two or more processing stations, and exemplary processingstations for such systems, among others.

Example 1

This example describes an exemplary system for drilling and cuttingworkpieces driven along a linear path; see FIGS. 4 and 5.

FIG. 4 shows an exemplary system 130 for automated cutting (sawing) anddrilling of workpieces driven along a linear path. System 130 mayinclude a pusher mechanism 132 configured to push a workpiece 134 alonga linear path 136. System 130 also may include a saw station 138 and adrill station 140 disposed at spaced positions generally along thelinear path. The pusher mechanism thus may position the workpiecesuitably along the linear path so that the saw station and drill stationcan saw and drill the workpiece to form one or more workpiece products142. The workpiece may be supported by a table 144, guided by one ormore guide rails 146, and held in position by a selectively actuableclamp mechanism 148.

System 130 may include one or more controllers (computers) forautomating aspects of system operation. For example, the system mayinclude a local controller 150 and a project management controller 152.The local controller may be configured to send instructions to, and thuscontrol, each of the pusher mechanism, the saw station, and the drillstation, so that movement of the workpiece along the linear path,cutting the workpiece, and drilling the workpiece each are automated.The local controller also may send instructions to, and thus controlselective actuation (and de-actuation) of, the clamp mechanism. Thelocal controller further may be configured to receive input data aboutworkpieces and/or desired products, among others, and may optimize andcoordinate processing of workpieces by the saw station and the drillstation according to the products desired. Project management controller152 may be used remotely from the local controller, to store, edit,combine, or modify data about desired products (and/or workpieces), suchas cut/drill lists, prior to downloading one or more of the lists to thelocal controller.

Data (such as length, grade, type, etc.) about workpieces and/or systemoperation may be input by any suitable mechanism. For example, localcontroller 150 may include a keypad 154 through which data may be inputin by an operator of the system. Alternatively, or in addition, system130 may include an optical measuring device 156 that inputs data to thelocal controller based on a path followed by light 158. For example,interruption of the light path by an end of a future workpiece 160 to beprocessed after current workpiece 134, and/or by an object placedmanually (using human energy) in the light path, may be used to inputthe length of the future workpiece and/or a position(s) of a defect 162along the length of the future workpiece, among others. An audio/visualdevice, such as an indicator light 164, may be used to signal successful(and/or unsuccessful) input of data, such as length and/or defectpositions, to the local controller. Signals, such as processing start orstop signals, among others, also may be input by using the opticalmeasuring device as a “virtual keyboard” and/or with other userinterfaces, such as keypad 154, a graphical user interface, or a footpedal 165, among others.

System 130 also may include other devices or features to facilitateworkpiece management. For example, the system may include a printer 166configured to print labels 168 for manual or automatic application toworkpiece products. System 130 also or alternatively may include anoutfeed structure 169 configured to receive workpiece products, salvagepieces, and waste pieces. The outfeed structure may include a wasteopening 170 sufficient to selectively receive only waste pieces.Accordingly, the system may be configured to cut pieces, designated fordisposal, to a size small enough to fit through the waste opening.Further aspects of processing and separating salvage and waste piecesare described in U.S. patent application Ser. No. 10/645,828, filed Aug.20, 2003, which is incorporated herein by reference.

FIG. 5 shows selected portions of system 130, particularly portions ofsaw station 138 and drill station 140, and their relationship toworkpiece 134. Saw station 138 may include a saw blade 180 drivenrotationally or reciprocably by a motor. Control of the saw station bythe local controller may include moving the saw blade into engagementwith the workpiece, for example, by instructing the saw station to movethe saw blade upward, transverse, and/or downward to (and/or through)the workpiece. In the present illustration, the saw blade is instructedto cut the workpiece by transverse movement, shown at 181.

Drill station 140 may include a drill bit 182 driven to rotate and/orpivot by a motor to form one or more holes 183 in the workpiece.Operation of the drill station by the local controller may includeinstructing the drill station to move the drill bit into engagement withthe workpiece, for example, by movement that is upward, transverse,oblique, and/or downward into (and/or through) the workpiece. In thepresent illustration, the drill bit approaches and moves away from theworkpiece by downward and upward movement, respectively, along avertical axis, shown at 184. The depth of drilling may be controlled byhow far the drill bit is advanced into the workpiece. The drill stationalso may include a drive mechanism that moves the drill bit along atransverse axis, shown at 186 (and/or a longitudinal axis or verticalaxis, among others), to adjust the transverse (and/or longitudinal orvertical) position at which the drill bit enters the workpiece. In someexamples, the drill station may include a drive mechanism that permitsautomatic adjustment of the angle at which the drill bit drills theworkpiece. In the present illustration, the drill station is closer tothe pusher mechanism than the saw station. However, in alternativeembodiments, the saw station may be closer to the pusher mechanism thanthe drill station, or they may be disposed at about the same distancefrom the pusher mechanism.

Clamp mechanism 148 may include a drive mechanism 188. The drivemechanism may move the clamp mechanism along an axis, shown at 190, thatis transverse to the linear processing path, for example, a horizontalor vertical axis. The controller may be configured to instruct drivemechanism 188 when, where, and/or how to move, thus controlling itsoperation.

Example 2

This example describes an exemplary workpiece processing system withmultiple processing stations, including a print station for printingindicia on a workpiece driven past the print station; see FIGS. 6-7.

FIG. 6 shows a side view of a workpiece processing system 210 includinga print station 212. The print station may be configured to printindicia on a workpiece 214 driven along a linear path 216. The workpiecemay be supported during printing and other processing by a supportstructure, such as a table having a horizontal support surface 217. Theprint station may include a printhead 218, for example, an inkjetprinthead configured to fire ink droplets 220 onto a surface of theworkpiece, for example, upper surface 222. The printhead may include aplurality of nozzles, from which individual droplets may be fired, suchas by actuation of thin-film firing elements (e.g., thin-film heaterelements and/or piezoelectric elements, among others). The print stationmay be fixed or movable during operation, for example, movabletransverse to the linear path of workpiece movement. If fixed, the printstation may print indicia while the workpiece is moving or not movingalong the linear path. Operation of the print station while theworkpiece is moving may increase the speed of workpiece processing,relative to printing only when the workpiece is stopped. In someexamples, operation of the printhead may be coordinated with theposition of the workpiece, based on an encoder in the workpiece drivemechanism.

FIG. 7 shows a plan view of system 210, taken generally along line 7-7of FIG. 6. In the present illustration, workpiece 214 includes fullyprinted indicia 224 where the workpiece has advanced past the printstation, and partially printed indicia 226 in the process of beingprinted by the print station. The indicia or surface marks may includeone or more lines 228, one or more alphanumeric characters 230, one ormore words, a bar code, a symbol, and/or the like. The indicia may beused, for example, to identify products and/or to guide additionalprocessing or assembly of products. For example, in the presentillustration, characters “A5” may identify a particular product or aparticular end of a product. The characters (or other indicia, such ascolors, symbols, etc.) also or alternatively may indicate whichcomponent (e.g., by name or part number) is to be assembled with themarked product, and vice versa, so that pairs of products may be markedto identify their partners for mating with one another. Line 228 maydefine, for example, an accurate position at which another component isto be attached to the workpiece (see Example 3).

Example 3

This example describes an exemplary workpiece processing system withmultiple processing stations, including a marking station for placing avisible surface mark (an indicium or indicia) on a workpiece driven pastthe marking station; see FIG. 8.

System 250 may include a marking station 252 that can place one or moresurface marks such as lines 254 on a workpiece 256. The marking stationmay include a marking instrument, such as a pen 258, an inkjet device(see Example 2), or a scoring device (such as a scribe or sharp-pointedawl), among others, that creates a surface mark with ink (or anothercolorant of any suitable color, including black) or by scratching theworkpiece surface, as the marking instrument moves across the workpiece.The marking instrument may be configured to form a mark that extendslinearly (or nonlinearly) in a direction orthogonal, oblique, orparallel to the linear path 260 followed by the workpiece. An orthogonalmark may be formed by orthogonal movement of the marking instrumentwhile the workpiece is not moving. Alternatively, or in addition, anorthogonal mark may be formed while the workpiece is moving, by obliquemovement of the marking instrument, shown at 262, for example, along anobliquely disposed guide rail 264. The oblique movement may have anangle, for example 45°, and a speed selected so that the speed offorward movement of the workpiece along the linear path matches thespeed of the marking instrument for travel parallel to the linear path.Alternatively, an oblique mark may be formed while the workpiece ismoving or not moving. In some examples, the marking instrument may bereplaced with a cutting instrument, such as a saw, to provide a flyingcrosscut that is created as the workpiece is moving. In any case,operation of the marking instrument or cutting instrument may becontrolled by a computer and coordinated with operation of a drivemechanism that moves the workpiece along a linear path.

System 250 may be useful, for example, in forming parts for kitchencabinets. Kitchen cabinets generally have a face frame that sits behinddoors and/or drawers. The face frame may have a top rail, a bottom rail,and one or more intermediary rails each attached to opposing stiles. Theposition for future attachment of the intermediary rails may be markedon a workpiece (particularly a portion of the workpiece corresponding toa future stile) using marking station 252 of system 250. In someexamples, marks may be placed on a workpiece before (and/or duringand/or after) the workpiece is cut by a saw station of a processingsystem.

Example 4

This example describes an exemplary workpiece processing system withmultiple processing stations, including a spacer placement station; seeFIG. 9.

System 280 may include a spacer placement station 282 that adds spacerelements (such as spacer balls 284, foam blocks, one or more rubbersplines, etc.) to a workpiece 286. The spacer elements may be used, forexample, to allow a panel in a frame and panel door to be free-floating,to allow the panel to expand and contract, and/or to dampen panelrattling, among others. The spacer elements may be configured to bereceived in a cavity formed in the workpiece, for example, alongitudinal groove 288. The longitudinal groove or other cavity may beformed upstream of the spacer placement station within system 280, forexample, using a rip saw or a router that is oriented to cutlongitudinally (with or without concurrent workpiece movement).Alternatively, the groove or other cavity may be formed outside ofsystem 280 before the workpiece is processed by the system. The spacerplacement station 282 may be configured to fire the spacer elements,shown at 290, at the workpiece without direct contact with theworkpiece, as shown in the present illustration. For example, the spacerplacement station may include a modified paint ball gun or similarfiring device that can fire the spacer elements at the workpiece.Accordingly, in some examples, the spacer elements may be added to theworkpiece while the workpiece is moving (and, generally, with the spacerplacement station not moving), to save processing time. The spacerplacement station may fire spacer elements vertically, as shown in thepresent illustration, horizontally, or along any other suitable path.Alternatively, a spacer(s) may be pressed into the groove or othercavity. In some examples, the spacer elements may be slightly oversized,so that they deform and stay in position when placed into the groove orother cavity.

Controller software may be configured to calculate where and/or whenspacer elements should be fired at workpieces, as the workpieces aremoving past the spacer placement station. For example, positions along aworkpiece at which spacer elements are to be added may be determined bythe controller software according to stored specifications of desiredproducts. In particular, the controller software may determine whichproduct or products are being produced from the workpiece, which of theproduced products, if any, should include spacer elements, and whatposition or positions along the length of each product should include aspacer element. The positions of spacer elements may be predefined ormay be calculated “on the fly.” In an exemplary embodiment, spacer ballsare placed three inches from each end of rails and two inches from eachend on stiles. The software thus may include an algorithm thatdetermines the length and part description of each product to be formedfrom a workpiece, and based on these two factors, calculates both theplacement and frequency of spacer elements to be inserted and in turnthe actual ordinate positions along the length of the workpiece.Accordingly, the spacer elements may be added to selected workpiecesautomatically and at predefined positions within these selectedworkpieces, in some cases while the workpieces are moving and/or withoutcontacting the workpieces with the spacer placement station.

Example 5

This example describes exemplary workpiece processing systems withmultiple processing stations, including a station for forming a jointsurface.

Joints are sites where two or more components are joined together. Eachcomponent includes a joint surface that mates with a complementary jointsurface of an adjacent component. Exemplary joint surfaces formed byworkpiece processing may be joined with each other to produce fingerjoints, miter joints, mortise and tenon joints, dovetail joints, dadojoints, lap joints, splined joints, tongue and groove joints, and/or thelike.

A joint surface for joining to a complementary joint surface may beformed by removing material from any suitable surface of a workpieceusing the systems of the present teachings. Accordingly, the jointsurface may be formed on an end of a workpiece, an edge of a workpiece,and/or a face of a workpiece. For example, a mortise for a tenon (or atenon for a mortise) may be routed automatically from a face, edge, orend of a workpiece. In some examples, the joint surface may be formed asa workpiece is cut, for example, a butt joint surface formed by anorthogonal crosscut, or a miter joint surface formed by a miter cut. Insome examples, the joint surface may be formed on a cut end produced bycutting the workpiece in a system of the present teachings. For example,a finger joint surface may be formed with the newly cut end of aworkpiece using a finger joint cutter after the workpiece has been cutby a saw station. After cutting, the newly created ends of the leadingand trailing pieces may be separated, for example, by advancing theleading piece with a conveyor. The leading and/or trailing piece thenmay be clamped in position and automatically processed with a stationthat cuts finger joints.

Example 6

This example describes exemplary workpiece processing systems withmultiple processing stations, including a station for forming a cavityand another station for inserting a joining member into the cavity.

Joints may be strengthened by using joining members that span joints.Such joining members may strengthen joints, for example, by increasingthe surface area of a joint (and thus the surface area for a glue)and/or may swell after their installation, among others. Exemplaryjoining members include dowels, biscuits (used, for example, to spanmiter joints in frames), butterfly locks, or the like.

Processing systems of the present teachings may include processingstations configured to install joining members into workpiecesautomatically. The systems may include a processing station that forms areceiver cavity in a workpiece, and another processing station thatinserts the joining member into the receiver cavity. The receiver cavityand the joining member may have complementary structure, so that aportion of the joining member fits into the receiver cavity, sometimesrelatively snugly. In some examples, the joining member may include acoating of an adhesive when it is inserted. Alternatively, the receivercavity may be processed at a glue station at which glue is injectedautomatically into the receiver cavity before the joining member isinserted. A partner component of the processed workpiece, with acomplementary joint surface then may be joined with the workpiece andits joining member, to complete the joint. Joining the partner componentmay be performed outside the processing systems or automatically by theprocessing systems.

Example 7

This example describes exemplary workpiece processing systems withmultiple processing stations, including a drill station for forming apocket hole in a workpiece.

Pocket holes are obliquely oriented holes that may be used, for example,to receive fasteners, such as screws, to secure a joint, such as a buttjoint. The systems of the present teachings may be used to form pocketholes automatically. In some examples, the systems also may include asaw station. The pocket holes near an end of a workpiece product may beformed before or after the workpiece is cut. In exemplary embodiments,pocket holes configured to receive screws to join face frame members aredrilled after cutting a workpiece to length.

Example 8

This example describes exemplary workpiece processing systems withmultiple processing stations for processing workpieces formed of metal.

The systems may be configured to cut and remove burrs from metal.Accordingly, the systems may include a cutting station (such as a sawstation) and a deburring station. The systems may cut a metal workpieceto produce a newly cut end, and then may move the workpiece to thedeburring station to remove any sharp edges of the newly cut end. Thedeburring station may include, for example, a rotating metal brushand/or a rotating wheel with sandpaper flaps, among others.

The systems may be configured to cut metal and then notch the newly cutend. Accordingly, the systems may include a cutting station (such as asaw station) and a notching station. After cutting a workpiece toproduce a newly cut end, the systems may move the workpiece to thenotching station for notching for the newly cut end. The resultantnotched product may be suitable, for example, as a structural member ofa window blind. The notched end may be configured to receive an end cap,so that a fastener or a string, among others, can be received in thenotch.

The systems may be configured for automatic insertion of rivets. Therivets may include fastener structure, for example, a female or malethread, or a bracket, among others. The rivets may be inserted into aworkpiece before, during, and/or after the workpiece is cut to length.

The systems may be configured for automaticaly tapping holes (that is,forming a thread in the holes). The systems may include a drill stationand a tap station. A hole may be drilled automatically in a metalworkpiece and then tapped afterward. In some embodiments, the tapstation may be disposed downstream of the drill station. In someembodiments, the drill station and the tap station may be configured todrill and tap a hole while the workpiece is in the same position, thatis, without moving the workpiece between operations.

The systems may be configured to automatically place fasteners intoholes. The systems may include a drill station and a fastener placementstation. After a hole is drilled in a workpiece, the fastener placementstation may press a self-clinching fastener, such as PEM stud or nut,into the hole.

The systems may be configured to deform metal workpieces automatically.The systems may include a cutting station (such as a saw station) and adeformation station. Before, during, and/or after a workpiece is cut,the workpiece may be deformed, for example, bent, twisted, stamped,formed, etc. Deformation may be conducted, for example, by a pressbrake.

The systems may be configured to punch holes automatically. The systemsmay include a cutting station (such as a saw station) and a punchstation. Before, during, and/or after a workpiece is cut to length,holes may be punched in the workpiece. Punching may be suitable, forexample, in the window industry to provide an attachment site within analuminum, perimeter frame member for an intermediate frame member of awindow frame.

Example 9

This example describes exemplary workpiece processing systems withmultiple processing stations that process workpieces for assembly ofmiter-fold boxes.

The systems may include a V-grooving machine and a glue station. Thesystems optionally may cut a workpiece to length. The V-grooving machinemay form V-shaped transverse grooves in a face of the workpiece, before,during, and/or after cutting the workpiece to length. The groovesgenerally do not extend to the opposing face of the workpiece, forexample, leaving a plastic backing of the workpiece uncut. The gluestation then may apply glue to the V-grooves. The grooved workpiece withglue then may be folded to mate opposing surfaces of each V-groove, toform the sides of a box, optionally in the presence of a panel that fitsinto longitudinal grooves disposed on the sides. Folding may beperformed automatically by the system, or manually or automaticallyoutside the system. This resulting box may provide a drawer or speakerbox, among others.

Example 10

This example describes exemplary workpiece processing systems withmultiple processing stations that process workpieces for bending.

In the packaging industry, corner cushioning pieces (e.g., formed ofcardboard or foam) may need to be cut to length from stock, and scoredfor bending. The systems thus may include a cutting station and ascoring station, which may operate in any suitable order on a workpiece.

Example 11

This example describes exemplary workpiece processing systems withmultiple processing stations and configured to sort processed products.The systems may include various chutes or gates that may be operatedautomatically. Operation of the chutes or gates may be determined by asorting algorithm that controls sorting of workpiece products accordingto product identity, product type, sets of related products, etc., sothat the products are sorted into appropriate bins.

Example 12

This example describes exemplary workpiece processing systems withmultiple processing stations, including a station for boring/drillingholes for attaching hinges. Hinge holes may be formed in door framemembers and face frame members automatically, before, during, and/orafter cutting the members to length.

Example 13

This example describes exemplary combinations of processing stationsthat may be included in the systems of the present teachings.

A processing system may include any suitable combination of two, three,four, or more processing stations, such as any of the processingstations of the present teachings. In some examples, the processingsystem may include a cutting station, such as a saw station, and atleast one other processing station. The at least one other processingstation may include a marking station, a printing station, a drillingstation, a router station, a deburring station, a scoring station, afluid-addition station (for application of paint, glue, varnish, etc.),a member addition station (for addition of one or more members, such asa dowels, biscuits, butterfly locks, fasteners, spacers, labels, etc.),a shearing station, a deformation station, a punching station, a foldingstation, a cutting station (such as a second saw station), a sandingstation, and/or the like. In some examples, the processing system mayinclude a cutting station (such as a saw station) and a marking station(such as a scoring, printing, or line-drawing station for creating asurface mark on a workpiece), and at least a third processing station(such as a drill station, a second cutting station, a routing station(with a router that removes material from the workpiece), afluid-addition station, a member-addition station, etc.).

The stations may have any suitable disposition relative to each otherand relative to a workpiece drive mechanism. In some examples, a firststation may be disposed in a first position closest to the drivemechanism, a second station may be disposed in a second position that isspaced farther from the drive mechanism than the first position, and,optionally, third and/or higher order stations may be disposed in thirdand higher positions disposed farther from the workpiece drive mechanismthan lower order positions. Each of the first, second, third, fourth, orhigher order station may be a cutting station, a drill station, amarking station, a router station, a member-addition station, a fluidaddition station, or any other processing station described herein. Insome examples, first and second processing stations may be disposed withthe second processing station closest to the drive mechanism, that is,so that regions of a workpiece are moved through the second processingstation before the first processing station.

The disclosure set forth above may encompass multiple distinctinventions with independent utility. Although each of these inventionshas been disclosed in its preferred form(s), the specific embodimentsthereof as disclosed and illustrated herein are not to be considered ina limiting sense, because numerous variations are possible. The subjectmatter of the inventions includes all novel and nonobvious combinationsand subcombinations of the various elements, features, functions, and/orproperties disclosed herein. The following claims particularly point outcertain combinations and subcombinations regarded as novel andnonobvious. Inventions embodied in other combinations andsubcombinations of features, functions, elements, and/or properties maybe claimed in applications claiming priority from this or a relatedapplication. Such claims, whether directed to a different invention orto the same invention, and whether broader, narrower, equal, ordifferent in scope to the original claims, also are regarded as includedwithin the subject matter of the inventions of the present disclosure.

1. A method of constructing a face frame component for a cabinetcomprising providing a cut list including dimensions of processed piecesrequired for construction of face frames for cabinets, providing anapparatus configured to cut length dimensions and to rout a cavity in awork piece in a single pass through the apparatus, and a computerconnected to the apparatus, the apparatus having a linear processingpath, a pusher configured for reciprocal movement along a length of theprocessing path to push a trailing end of an elongate work piece havinga long axis parallel to the processing path, and a plurality ofprocessing stations arranged along the processing path downstream fromthe pusher, at least one of the stations including a saw orientatedperpendicular to the processing path for cutting the work piece in adirection perpendicular to the long axis of the work piece, and at leastone of the stations including a router bit configured to form a cavityin the work piece, programming the computer with an optimization programconfigured to calculate an optimum processing plan for a work piecebased on a starting length of the work piece, and current requirementsspecified in the cut list stored in the computer, entering the cut listinto the computer, providing a supply of work pieces for processing intodimensions specified in the cut list, each workpiece being preprocessedinto a substantially straight form having a rectangular cross-section.selecting a first work piece from the supply, inputting data into thecomputer including the length of the first work piece, calculating inthe computer an optimum plan for processing the first work piece tosatisfy current cut list requirements, driving the pusher, undercomputer control, along a length of the processing path to push thetrailing end of the first work piece down the processing path toward theprocessing stations, cutting the work piece, under computer control,perpendicular to the long axis of the first work piece at a firstprocessing station, and routing a cavity in the first work piece at asecond processing station.
 2. The method of claim 1, wherein the cavitycreated by the routing step forms a mortise, further comprising the stepof assembling a face frame component for a cabinet by forming a mortiseand tenon joint between the first work piece and a second work piece. 3.The method of claim 1, wherein the cavity created by the routing stepforms a longitudinal groove, further comprising the step of inserting aspacer element in the groove.
 4. The method of claim 3, wherein theinserting step is performed by shooting the spacer element toward thegroove.
 5. The method of claim 1 further comprising inputting data intothe computer indicating location of one or more defects including knots,cracks, or discoloration within the work piece, wherein the calculatingstep includes calculating an optimum plan for processing the workpieceto satisfy current cut list requirements, and removing the one or moredefects.
 6. The method of claim 4, wherein the shooting step is carriedout during the driving step.
 7. The method of claim 3, wherein thespacer element is oversized relative to a dimension of the groove. 8.The method of claim 3, wherein the programming step includes programmingthe computer to determine which workpieces should include spacerelements.
 9. The method of claim 3, wherein the programming stepincludes programming the computer to determine a location for a spaceralong a length of a workpiece.
 10. The method of claim 1 furthercomprising the step of providing a marking station along the processingpath of the apparatus, and marking the first work piece at the markingstation to indicate a position of attachment between a rail and a stilefor a cabinet.
 11. The method of claim 1 further comprising the step ofproviding a printing station along the processing path, and printing alabel for the first workpiece indicating a characteristic or future usefor the workpiece.
 12. The method of claim 11, wherein the label isprinted directly on the first workpiece.